Use of Development Test Benches for Fast-Rotating Rotor Systems to Increase Product Maturity

• Applicant: Professor Dr.-Ing. Sven Matthiesen
• Subject Area: Engineering Design, Machine Elements, Product Development
• Term: from 2019 to 2021
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 429569390

In the case of fast-rotating drive systems embedded in polymer housings, the coordination of drive train and polymer housing with the vibration behaviour of the system, e.g. with regard to the mounting of gear stages, is a core challenge of product development. Studies on the influence of vibrations on fast-rotating gear stages are currently the subject of research. The design engineer is faced with the challenge of deriving suitable design target values from the development goals.The aim of the application is to develop a methodical procedure for deriving design properties of polymer housings for reducing vibrations in fast-rotating rotor systems. In this project, analytical methods and development test benches are jointly used to gain design relevant insights.On the basis of existing design and analysis methods, a qualitative effect structure for a generic angular drive with bevel gear stage will be created. The development goal for the angle drive is to reduce the component load on the gearing caused by the vibration excitation of the drive train. The embodiment-function relationship of the drive system to be investigated is analyzed. First, the system behavior is determined with the help of simulation models and mapped in effect grid. By means of a sensitivity analysis, the design properties with high functional relevance are determined and the quantitative correlations are investigated by experimental investigations on a development test bench. From the knowledge gained, a component with the desired properties is developed. This component is then integrated into the drive system and validated on the development test bench. The knowledge gained is used to develop the methodical approach. The focus here is deliberately on joint research into the system and the associated methods.The result is a parametric effect structure which is explicit for the investigated drive system and with which the relationship between design properties and system behaviour is described. Furthermore, a methodical procedure is available as a result, how design relevant findings can be generated with the help of analytical methods and development test benches. With this work, it is possible for the first time to determine quantitative effect structures with the help of a combination of development test bench and methodical support and thus to obtain target values for the design.

• DFG Programme: Research Grants